Synthesis of small diameter single-walled carbon nanotubes

ABSTRACT

Methods, processes, and apparatuses for the large scale synthesis of single-walled carbon nanotubes having small diameters are provided. Metal catalysts having small diameter and narrow distribution of particle sizes are prepared and continuously injected as aerosols into a reactor. The metal catalysts are supported on supports that are substantially free of carbon, and the reactor is configured to control the flow of the gases such that the reaction time and contact of the reactants with the reactor walls can be controlled. Single-walled carbon nanotubes can be continuously synthesized at a large scale and with high yields, and with small diameters and with narrow diameter ranges.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims the benefit of U.S. provisional patentapplication No. 60/678,668, filed on May 5, 2005, which is hereinincorporated by reference in its entirety.

FIELD OF INVENTION

The present invention relates to methods for the synthesis of carbonnanotubes having small diameters and carbon nanostructures.

BACKGROUND

Carbon nanotubes are hexagonal networks of carbon atoms forming seamlesstubes with each end capped with half of a fullerene molecule. They werefirst reported in 1991 by Sumio Iijima who produced multi-layerconcentric tubes or multi-walled carbon nanotubes having up to sevenwalls by evaporating carbon in an arc discharge. In 1993, Iijima's groupand an IBM team headed by Donald Bethune independently discovered that asingle-wall nanotube could be made by vaporizing carbon together with atransition metal such as iron or cobalt in an arc generator (see Iijimaet al. Nature 363:603 (1993); Bethune et al., Nature 363: 605 (1993) andU.S. Pat. No. 5,424,054). The original syntheses produced low yields ofnon-uniform nanotubes mixed with large amounts of soot and metalparticles.

Presently, there are three main approaches for the synthesis of single-and multi-walled carbon nanotubes. These include the electric arcdischarge of graphite rod (Joumet et al. Nature 388: 756 (1997)), thelaser ablation of carbon (Thess et al. Science 273: 483 (1996)), and thechemical vapor deposition of hydrocarbons (Ivanov et al. Chem. Phys.Lett 223: 329 (1994); Li et al. Science 274: 1701 (1996)). Multi-walledcarbon nanotubes can be produced on a commercial scale by catalytichydrocarbon cracking while single-walled carbon nanotubes are stillproduced on a gram scale.

Generally, single-walled carbon nanotubes are preferred overmulti-walled carbon nanotubes because they have fewer defects and aretherefore stronger and more conductive than multi-walled carbonnanotubes of similar diameter. Defects are less likely to occur insingle-walled carbon nanotubes because multi-walled carbon nanotubes cansurvive occasional defects by forming bridges between unsaturated carbonvalances, while single-walled carbon nanotubes have no neighboring wallsto compensate for defects. Defect-free single-walled nanotubes areexpected to have remarkable mechanical, electronic and magneticproperties that could be tunable by varying the diameter, and chiralityof the tube.

Presently, there are two types of chemical vapor deposition for thesyntheses of single-walled carbon nanotubes that are distinguishabledepending on the form of supplied catalyst. In one, the catalyst isembedded in porous material or supported on a substrate, placed at afixed position of a furnace, and heated in a flow of hydrocarbonprecursor gas. Cassell et al. (1999) J. Phys. Chem. B 103: 6484-6492studied the effect of different catalysts and supports on the synthesisof bulk quantities of single-walled carbon nanotubes using methane asthe carbon source in chemical vapor deposition. They systematicallystudied Fe(NO₃)₃ supported on Al₂O₃, Fe(SO₄)₃ supported on Al₂O₃, Fe/Rusupported on Al₂O₃, Fe/Mo supported on Al₂O₃, and Fe/Mo supported onAl₂O₃—SiO₂ hybrid support. The bimetallic catalyst supported on thehybrid support material provided the highest yield of the nanotubes. Suet al. (2000) Chem. Phys. Lett. 322: 321-326 reported the use of abimetal catalyst supported on an aluminum oxide aerogel to producesingle-walled carbon nanotubes. They reported preparation of thenanotubes is greater than 200% the weight of the catalyst used. Incomparison, similar catalyst supported on Al₂O₃ powder yieldsapproximately 40% the weight of the starting catalyst. Thus, the use ofthe aerogel support improved the amount of nanotubes produced per unitweight of the catalyst by a factor of 5. In the second type of carbonvapor deposition, the catalyst and the hydrocarbon precursor gas are fedinto a furnace using the gas phase, followed by the catalytic reactionin a gas phase. The catalyst is usually in the form of a metalorganic.Nikolaev et al. (1999) Chem. Phys. Lett. 313: 91 disclose ahigh-pressure CO reaction (HiPCO) method in which carbon monoxide (CO)gas reacts with the metalorganic iron pentacarbonyl (Fe(CO)₅) to formsingle-walled carbon nanotubes. It is claimed that 400 g of nanotubescan be synthesized per day. Chen et al. (1998) Appl. Phys. Lett. 72:3282 employ benzene and the metalorganic ferrocene (Fe(C₅H₅)₂) deliveredusing a hydrogen gas to synthesize single-walled carbon nanotubes. Thedisadvantage of this approach is that it is difficult to controlparticles sizes of the metal catalyst. The decomposition of theorganometallic provides the metal catalyst having variable particle sizethat results in nanotubes having a wide distribution of diameters.Further, the decomposition of the metalorganic precursor forms carbonstructures that are not desired.

In another method, the catalyst is introduced as a liquid pulse into thereactor. Ci et al. (2000) Carbon 38: 1933-1937 dissolve ferrocene in 100mL of benzene along with a small amount of thiophene. The solution isinjected into a vertical reactor in a hydrogen atmosphere. The techniquerequires that the temperature of bottom wall of the reactor had to bekept at between 205-230° C. to obtain straight carbon nanotubes. In themethod of Ago et al. (2001) J. Phys. Chem. 105: 10453-10456, colloidalsolution of cobalt:molybdenum (1:1) nanoparticles is prepared andinjected into a vertically arranged furnace, along with 1% thiophene andtoluene as the carbon source. Bundles of single-walled carbon nanotubesare synthesized.

The properties of the carbon SWNTs, such as the electronic structure,the optical properties, and the like, depend on the diameter of the tubeand the structure of the tubes. Thus, the controllable synthesis ofcarbon SWNTs is important for creating nanostructures. The synthesis ofcarbon SWNTs with narrow diameter range between 0.8-1.1 nm is disclosedby Maruyama et al. Chem. Phys. Lett. 375: 553-559 (2003), whereiron-cobalt bimetallic catalyst particles is supported with zeolitepowder and exposed to fullerene vapor in a heated quartz tube furnace.In another method (Jeong et al. Chem. Phys. Lett. 380: 263-268 (2003)),nickel catalyst supported on MgO is used to grow SWNTs at 800° C. usingacetylene and hydrogen gases, with the diameter of the SWNTs in therange of 0.7-1.0 nm. Carbon SWNTs with an average diameter of 0.81 nmare synthesized (Bachilo et al. J. Am. Chem. Soc. 125: 11186-11187(2003)) using the cobalt-molybdenum biocatalyst supported on silica andheated to 750° C. in the presence of hydrogen gas and helium gas, andthen exposed to carbon monoxide. In another method (Ciuparu et al. J.Phys. Chem. B. 108(2): 503-507 (2004)), the diameter of the carbon SWNTis controlled between 0.5 and 0.8 nm range by varying the pore diameterof the catalyst (cobalt in MCM-41) between 1.9 and 2.9 nm, and usingcarbon monoxide as the carbon source.

The methods discussed above produce carbon SWNTs in small yields. Thus,there is a need for methods for larger scale synthesis of carbonnanotubes having a narrow diameter range. Preferably, the method allowsfor the growth of carbon nanotubes of a desired type, such assingle-wall nanotubes, and with little or no impurities.

SUMMARY

The present invention provides methods, apparatuses, and processes forthe continuous production of carbon nanostructures, such assingle-walled carbon nanotubes (SWNTs) having small diameters within anarrow range. In one aspect, metal particles having controlled particlesize and/or diameter are supported on non-carbon containing powderedoxide supports. The resulting metal nanoparticles are used as a growthcatalyst for the growth of carbon nanotubes. The supported metalnanoparticles are entrained in a gas and delivered into the reactionchamber as an aerosol. Additionally, carbon precursor gas, such asmethane, is provided in the reaction chamber. The flow of the reactantsand products through the reaction chamber is controlled such that theircontact with the reaction vessel walls is minimized. The reactants areheated to a temperature below about 1000° C., and the product isseparated. The product is separated by guiding transport gas stream,having carbonaceous material comprising the carbon nanotubes andimpurities entrained in it, into one or more cyclone separator;collecting the impurities in the separator; and collecting the outletgas exiting the separator wherein carbon nanotubes are entrained in theoutlet gas. In one aspect, the transport gas can be guided into aplurality of cyclone separators and the solid in each separator can becollected. The plurality of cyclone separators can be attached to eachother sequentially and in such a manner that the heavier particles arecollected before the lighter particles.

These and other aspects of the present invention will become evidentupon reference to the following detailed description. In addition,various references are set forth herein which describe in more detailcertain procedures or compositions, and are therefore incorporated byreference in their entirety.

BRIEF DESCRIPTION OF DRAWINGS

FIG. 1 illustrates a reaction chamber for the production ofsingle-walled carbon nanotubes (SWNTs) having narrow diameterdistribution.

FIG. 2 depicts an apparatus for the production of carbon SWNTs of thepresent invention wherein the SWNTs have narrow diameter distribution.

FIG. 3 illustrates the TEM images of the as-synthesized carbon SWNTsgrown by the methods of the present invention and collected from thefirst separator.

FIG. 4 illustrates the temperature programmed oxidation (TPO) curves.FIG. 4 a illustrates the TPO curves of the as-synthesized carbonproducts grown by the methods of the present invention and collectedfrom the first separator, second separator, and the third separatorusing approximately 2700 sccm of transport gas flow and, for comparison,the TPO curves for carbon products collected from “horizontal” CVDexperimental setup using approximately 500 sccm of transport gas flow.FIG. 4 a illustrates TPO profiles of the SWNTs purified from the firstseparator using the horizontal CVD experimental setup.

FIG. 5 illustrates the Raman active breathing modes of as preparedcarbon SWNTs collected from the first separator, second separator, andthe third separator using laser excitations of 1064, 785, 532, and 488nm.

DETAILED DESCRIPTION

I. Definitions

Unless otherwise stated, the following terms used in this application,including the specification and claims, have the definitions givenbelow. It must be noted that, as used in the specification and theappended claims, the singular forms “a,” “an” and “the” include pluralreferents unless the context clearly dictates otherwise. Definition ofstandard chemistry terms may be found in reference works, includingCarey and Sundberg (1992) “Advanced Organic Chemistry 3^(rd) Ed.” Vols.A and B, Plenum Press, New York, and Cotton et al. (1999) “AdvancedInorganic Chemistry 6^(th) Ed.” Wiley, New York.

The terms “single-walled carbon nanotube” or “one-dimensional carbonnanotube” are used interchangeable and refer to cylindrically shapedthin sheet of carbon atoms having a wall consisting essentially of asingle layer of carbon atoms, and arranged in an hexagonal crystallinestructure with a graphitic type of bonding.

The term “multi-walled carbon nanotube” as used herein refers to ananotube composed of more than one concentric tubes.

The terms “metalorganic” or “organometallic” are used interchangeablyand refer to co-ordination compounds of organic compounds and a metal, atransition metal or a metal halide.

The term “passivating solvent” as used herein refers to an organicsolvent that will not co-ordinate with the metal ions, and that issuitable for use in thermal decomposition reactions.

The term “halogen” as used herein refers to fluoro, bromo, chloro and/oriodo.

The term “lower alkoxy” refers to the oxides of lower alkyl groups.Examples of lower alkyl groups include, but are not limited to, methyl,ethyl, propyl, isopropyl, butyl, isobutyl, sec-butyl, tert-butyl,pentyl, n-hexyl, octyl, dodecyl, and the like. The oxides includemethoxide, ethoxide, butoxide, and the like.

II. Overview

The present invention discloses methods, apparatus, and processes forthe large-scale manufacture of carbon nanotubes and structures composedof carbon nanotubes, preferably single-wall nanotubes.

The methods, apparatuses, and processes of the present invention are forsynthesizing carbon nanotubes, preferably single-walled carbon nanotubeson a large scale. Catalyst particles of controlled particle size andsurface area are isolated and injected into a reactor in the form of anaerosol. A carbon precursor gas is concomitantly introduced into thereactor. The flow of the gases within the reactor chamber is controlledsuch that minimum amount of carbon deposition occurs on the interiorwalls of the reaction chamber. The carbon nanotubes thus produced arecollected and purified.

The methods, apparatuses, and processes disclosed herein areadvantageous in that the particle size, diameter distribution, andsurface area of the catalyst particle can be controlled, therebyproviding control over the size, shape, type, and properties of thecarbon nanotubes formed during the chemical deposition process. Inaddition, the metal particles that act as catalysts are supported onwell characterized porous powders, such al Al₂O₃, instead of supportscontaining organic materials. Therefore, undesired carbon materials andother impurities are not produced. The invention thus provides formulti-gram synthesis of carbon nanotubes that are substantially free ofcontaminants.

III. The Reaction Vessel

In one aspect of the invention, a system for producing carbon nanotubesis provided. The system comprises a reactor capable of maintaining thereaction temperature and having an air-tight chamber where a source ofmetal catalyst particles as an aerosol, a source of carbon precursor gasand a source of inert gases is provided. The system can additionallycomprise an evacuating system connected to the reactor for evacuatinggases from the chamber, and/or a collection system for collecting,filtering, and enriching the nanotubes. The system, process and methodsof the present invention are described with reference to theaccompanying figures, where like reference numerals indicate identicalor functionally similar elements. Also in the figures, the left mostdigit of each reference numeral corresponds to the figure in which thereference numeral is first used.

The reaction vessel can be any conventional furnace configured to allowfor control over gas flows within a heated reaction chamber. Forexample, the reaction vessel can be the horizontal reaction vessel, suchas the Carbolite model TZF 12/65/550, or it can be a vertical reactionvessel. The reaction vessel is preferably a vertical reaction vessel 100illustrated in FIG. 1. The reaction chamber 110 can be a quartz tubeplaced inside the furnace having a means of heating 120 the reactionchamber to the desired temperature required for the growth of the carbonnanotubes. The reaction chamber may be maintained at the appropriatetemperature by 1) preheating the carbon precursor gases, 2) preheatingthe inert gases, 3) preheating the metal catalyst particles on powdersupports, 4) externally heating the reaction chamber, 5) applyinglocalized heating in the reaction chamber, such as by laser, inductioncoil, plasma coil, or any combination of the foregoing. Gas inlets 210,220, and 230 provide flows of the inert and regent gases and thecatalyst during operation of the furnace. Downstream recovery of theproduct produced by this process can be affected by known means such asfiltration, centrifugation and the like. For example, the product iscollected at the bottom of the furnace and separated using a separator300. A plurality of separators can be attached to the apparatus ifdesired.

In one aspect, the metal nanoparticles, in the form of an aerosol, areintroduced into the reaction chamber 110 via inlet 210. The methods andapparatuses for forming the aerosol are described in detail in thecommonly owned and co-pending U.S. patent application Ser. No.10/727,706 entitled “Dry Powder Injector” and filed on Dec. 3, 2003. Thecarbon precursor gas, optionally as a mixture with one or more othergases, is introduced into the reaction chamber via inlet 220. Inlets 210and 220 are positioned such that the flow of the catalyst and the carbonprecursor gas is substantially aligned with the long axis of thereaction chamber. In contrast, the inlet 230, which provides the meansfor the introduction of another gas, such as argon, into the reactionchamber, and the inlet is positioned at an angle relative to the longaxis of the reaction chamber. The angle of the gas inlet 230 will varydepending on the gas chosen, rate of flow of the gas, the geometry ofthe reaction chamber, the temperature of the reaction chamber, and thelike. The angle between the long axis of the reaction chamber and inlet230 can be 45° to about 90°, or any angle in between. The angle ispreferably about 70° to about 85°, or more preferably about 70° to about80°. The angle between the inlet 230 and the long axis is chosen suchthat the gas introduced through the inlet follows a helical path alongthe interior walls of the reaction chamber as it flows through it.Further, two or more “helical” inlets can be provided. The helical pathof the gas results in the reduction of deposition of carbon material onthe interior walls of the reaction chamber that normally occurs underchemical vapor deposition conditions. The gas inlet 230 can thus beadjusted to the angle that results in the reduction of carbondeposition. When gas inlet 230 is not properly aligned, the reactionchamber will quickly accumulate a black layer of sooth on the interiorwalls. Thus, in the reaction chamber composed of a transparent material,such as glass, proper alignment can be verified visually.

The components for the delivery system of gas flow can be connectedtogether using standard ½ inch stainless steel tubing. Conventional gassources, such as pressurized canisters with pressure regulators, can beused for gas sources. The amount of gas delivered to the inlets cantypically be controlled using standard mass flow controllers that arecommercially available.

Downstream recovery of the product produced by this process can beaffected by known means such as filtration, centrifugation and the like.

V. The Catalyst

The method, processes, and apparatuses of the present invention usemetal nanoparticles as the metallic catalyst. The metal or combinationof metals selected as the catalyst can be processed to obtain thedesired particle size and diameter distribution. The metal nanoparticlescan then be separated by being supported on a material suitable for useas a support during synthesis of carbon nanotubes using the metal growthcatalysts described below. Such materials include powders of crystallinesilicon, polysilicon, silicon nitride, tungsten, magnesium, aluminum andtheir oxides, preferably aluminum oxide, silicon oxide, magnesium oxide,or titanium dioxide, or combination thereof, optionally modified byaddition elements, are used as support powders. The metal nanoparticleson the support powders are injected as an aerosol into the reactionvessel. The function of the metallic catalyst in the carbon nanotubegrowth process is to decompose the carbon precursors and aid thedeposition of ordered carbon as nanotubes

The metal catalyst can be selected from a Group V metal, such as V orNb, and mixtures thereof, a Group VI metal including Cr, W, or Mo, andmixtures thereof, VII metal, such as, Mn, or Re, Group VIII metalincluding Co, Ni, Ru, Rh, Pd, Os, Ir, Pt, and mixtures thereof, or thelanthanides, such as Ce, Eu, Er, or Yb and mixtures thereof, ortransition metals such as Cu, Ag, Au, Zn, Cd, Sc, Y, or La and mixturesthereof. Specific examples of mixture of catalysts, such as bimetalliccatalysts, which may be employed by the present invention include Co—Cr,Co—W, Co—Mo, Ni—Cr, Ni—W, Ni—Mo, Ru—Cr, Ru—W, Ru—Mo, Rh—Cr, Rh—W, Rh—Mo,Pd—Cr, Pd—W, Pd—Mo, Ir—Cr, Ir—W, Ir—Mo, Pt—Cr, Pt—W, and Pt—Mo.Preferably, the metal catalyst is iron, cobalt, nickel, molybdenum, or amixture thereof, such as Fe—Mo, Co—Mo and Ni—Fe—Mo.

The metal, bimetal, or combination of metals are used to prepare metalnanoparticles having defined particle size and diameter distribution.The metal nanoparticles can be prepared by thermal decomposition of thecorresponding metal salt added to a passivating salt, and thetemperature of the solvent adjusted to provide the metal nanoparticles,as described in the co-pending and co-owned U.S. patent application Ser.No. 10/304,316, or by any other method known in the art. The particlesize and diameter of the metal nanoparticles can be controlled by usingthe appropriate concentration of metal in the passivating solvent and bycontrolling the length of time the reaction is allowed to proceed at thethermal decomposition temperature. Metal nanoparticles having particlesize of about 0.1 nm to about 100 nm, preferably about 1 nm to about 20nm, more preferably about 2 nm to about 11 nm and most preferably about3 nm to 7 nm can be prepared. The metal nanoparticles can thus have aparticle size of 0.1, 1, 2, 3, 4, 5, 6, 7, 8, 9, or 10 nm, and up toabout 20 nm. In another aspect, the metal nanoparticles can have a rangeof particle sizes. For example, the metal nanoparticles can haveparticle sizes in the range of about 3 nm and about 7 nm in size, about5 nm and about 10 nm in size, or about 8 nm and about 16 nm in size. Themetal nanoparticles can optionally have a diameter distribution of about0.5 nm to about 20 nm, preferably about 1 nm to about 15 nm, morepreferably about 1 mn to about 5 nm. Thus, the metal nanoparticles canhave a diameter distribution of about 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11,12, 13, 14, or 15 nm.

The metal salt can be any salt of the metal, and can be selected suchthat the melting point of the metal salt is lower than the boiling pointof the passivating solvent. Thus, the metal salt contains the metal ionand a counter ion, where the counter ion can be nitrate, nitride,perchlorate, sulfate, sulfide, acetate, halide, oxide, such as methoxideor ethoxide, acetylacetonate, and the like. For example, the metal saltcan be iron (II) sulfate heptahydrate, iron acetate (FeAc₂), nickelacetate (NiAc₂), palladium acetate (PdAc₂), molybdenum acetate (MoAc₃),ammonium heptamolibdate tetrahydrate, and the like, and combinationsthereof. The melting point of the metal salt is preferably about 5° C.to 50° C. lower than the boiling point, more preferably about 5° C. toabout 20° C. lower than the boiling point of the passivating solvent.

The metal salt can be dissolved in a passivating solvent to give asolution, a suspension, or a dispersion. The solvent is preferably anorganic solvent, and can be one in which the chosen metal salt isrelatively soluble and stable, and where the solvent has a high enoughvapor pressure that it can be easily evaporated under experimentalconditions. The solvent can be an alcohol, such as methanol, ethanol,propanol, and the like, or an ether, such as a glycol ether,2-(2-butoxyethoxy)ethanol, H(OCH₂CH₂)₂O(CH₂)₃CH₃, which will be referredto below using the common name dietheylene glycol mono-n-butyl ether,and the like.

The relative amounts of metal salt and passivating solvent are factorsin controlling the size of nanoparticles produced. A wide range of molarratios, here referring to total moles of metal salt per mole ofpassivating solvent, can be used for forming the metal nanoparticles.Typical molar ratios of metal salt to passivating solvent include ratiosas low as about 0.0222 (1:45), or as high as about 2.0 (2:1), or anyratio in between. Thus, for example, about 5.75×10⁻⁵ to about 1.73×10⁻³moles (10-300 mg) of FeAc₂ can be dissolved in about 3×10⁻⁴ to about3×10⁻³ moles (50-500 ml) of diethylene glycol mono-n-butyl ether.

In another aspect, more than one metal salt can be added to the reactionvessel in order to form metal nanoparticles composed of two or moremetals, where the counter ion can be the same or can be different. Therelative amounts of each metal salt used can be a factor in controllingthe composition of the resulting metal nanoparticles. For the bimetals,the molar ratio of the first metal salt to the second metal salt can beabout 1:10 to about 10:1, preferably about 2:1 to about 1:2, or morepreferably about 1.5:1 to about 1:1.5, or any ratio in between. Thus,for example, the molar ratio of iron acetate to nickel acetate can be1:2, 1:1.5, 1.5:1, or 1:1. Those skilled in the art will recognize thatother combinations of metal salts and other molar ratios of a firstmetal salt relative to a second metal salt may be used in order tosynthesize metal nanoparticles with various compositions.

The passivating solvent and the metal salt reaction solution can bemixed to give a homogeneous solution, suspension, or dispersion. Thereaction solution can be mixed using standard laboratory stirrers,mixtures, sonicators, and the like, optionally with heating. Thehomogenous mixture thus obtained can be subjected to thermaldecomposition in order to form the metal nanoparticles.

The thermal decomposition reaction is started by heating the contents ofthe reaction vessel to a temperature above the melting point of at leastone metal salt in the reaction vessel. Any suitable heat source may beused including standard laboratory heaters, such as a heating mantle, ahot plate, or a Bunsen burner, and the heating can be under reflux. Thelength of the thermal decomposition can be selected such that thedesired size of the metal nanoparticles can be obtained. Typicalreaction times can be from about 10 minutes to about 120 minutes, or anyinteger in between. The thermal decomposition reaction is stopped at thedesired time by reducing the temperature of the contents of the reactionvessel to a temperature below the melting point of the metal salt.

The size and distribution of metal nanoparticles produced can beverified by any suitable method. One method of verification istransmission electron microscopy (TEM). A suitable model is the PhillipsCM300 FEG TEM that is commercially available from FEI Company ofHillsboro, Oreg. In order to take TEM micrographs of the metalnanoparticles, 1 or more drops of the metal nanoparticle/passivatingsolvent solution are placed on a carbon membrane grid or other gridsuitable for obtaining TEM micrographs. The TEM apparatus is then usedto obtain micrographs of the nanoparticles that can be used to determinethe distribution of nanoparticle sizes created.

The metal nanoparticles, such as those formed by thermal decompositiondescribed in detail above, can then be supported on solid supports. Thesolid support can be silica, alumina, MCM-41, MgO, ZrO₂,aluminum-stabilized magnesium oxide, zeolites, or other oxidic supportsknown in the art, and combinations thereof. For example, Al₂O₃—SiO₂hybrid support could be used. Preferably, the support is aluminum oxide(Al₂O₃) or silica (SiO₂). The oxide used as solid support can bepowdered thereby providing small particle sizes and large surface areas.The powdered oxide can preferably have a particle size between about0.01 μm to about 100 μm, more preferably about 0.1 μm to about 10 μm,even more preferably about 0.5 μm to about 5 μm, and most preferablyabout 1 μm to about 2 μm. The powdered oxide can have a surface area ofabout 50 to about 1000 m²/g, more preferably a surface area of about 200to about 800 m²/g. The powdered oxide can be freshly prepared orcommercially available.

In one aspect, the metal nanoparticles are supported on solid supportsvia secondary dispersion and extraction. Secondary dispersion begins byintroducing particles of a powdered oxide, such as aluminum oxide(Al₂O₃) or silica (SiO₂), into the reaction vessel after the thermaldecomposition reaction. A suitable Al₂O₃ powder with 1-2 μm particlesize and having a surface area of 300-500 m²/g is commercially availablefrom Alfa Aesar of Ward Hill, Mass., or Degussa, N.J. Powdered oxide canbe added to achieve a desired weight ratio between the powdered oxideand the initial amount of metal used to form the metal nanoparticles.Typically, the weight ratio can be between about 10:1 and about 15:1.For example, if 100 mg of iron acetate is used as the starting material,then about 320 to 480 mg of powdered oxide can be introduced into thesolution.

The mixture of powdered oxide and the metal nanoparticle/passivatingsolvent mixture can be mixed to form a homogenous solution, suspensionor dispersion. The homogenous solution, suspension or dispersion can beformed using sonicator, a standard laboratory stirrer, a mechanicalmixer, or any other suitable method, optionally with heating. Forexample, the mixture of metal nanoparticles, powdered oxide, andpassivating solvent can be first sonicated at roughly 80° C. for 2hours, and then sonicated and mixed with a laboratory stirrer at 80° C.for 30 minutes to provide a homogenous solution.

After secondary dispersion, the dispersed metal nanoparticles andpowdered oxide can be extracted from the passivating solvent. Theextraction can be by filtration, centrifugation, removal of the solventsunder reduced pressure, removal of the solvents under atmosphericpressure, and the like. For example, extraction includes heating thehomogenized mixture to a temperature where the passivating solvent has asignificant vapor pressure. This temperature can be maintained until thepassivating solvent evaporates, leaving behind the metal nanoparticlesdeposited in the pores of the Al₂O₃. For example, if diethylene glycolmono-n-butyl ether as the passivating solvent, the homogenous dispersioncan be heated to 231° C., the boiling point of the passivating solvent,under an N₂ flow. The temperature and N₂ flow are maintained until thepassivating solvent is completely evaporated. After evaporating thepassivating solvent, the powdered oxide and metal nanoparticles are leftbehind on the walls of the reaction vessel as a film or residue. Whenthe powdered oxide is Al₂O₃, the film will typically be black. The metalnanoparticle and powdered oxide film can be removed from the reactionvessel and ground to create a fine powder, thereby increasing theavailable surface area of the mixture. The mixture can be ground with amortar and pestle, by a commercially available mechanical grinder, or byany other methods of increasing the surface area of the mixture will beapparent to those of skill in the art.

Without being bound by any particular theory, it is believed that thepowdered oxide serves two functions during the extraction process. Thepowdered oxides are porous and have high surface area. Therefore, themetal nanoparticles will settle in the pores of the powdered oxideduring secondary dispersion. Settling in the pores of the powdered oxidephysically separates the metal nanoparticles from each other, therebypreventing agglomeration of the metal nanoparticles during extraction.This effect is complemented by the amount of powdered oxide used. Asnoted above, the molar ratio of metal nanoparticles to powdered oxidecan be between about 1:10 and 1:15. The relatively larger amount ofpowdered oxide in effect serves to further separate or ‘dilute’ themetal nanoparticles as the passivating solvent is removed. The processthus provides metal nanoparticles of defined particle size.

As will be apparent to those of skill in the art, the catalyst thusprepared can be stored for later use. In another aspect, the metalnanoparticles can be previously prepared, isolated from the passivatingsolvent, and purified, and then added to a powdered oxide in a suitablevolume of the same or different passivating solvent. The metalnanoparticles and powdered oxide can be homogenously dispersed,extracted from the passivating solvent, and processed to increase theeffective surface area as described above. Other methods for preparingthe metal nanoparticle and powdered oxide mixture will be apparent tothose skilled in the art.

The metal nanoparticles thus formed can be used as a growth catalyst forsynthesis of carbon nanotubes, nanofibers, and other one-dimensionalcarbon nanostructures by a chemical vapor deposition (CVD) process.

VI. Carbon Precursors

The carbon nanotubes can be synthesized using carbon precursors, such ascarbon containing gases. In general, any carbon containing gas that doesnot pyrolize at temperatures up to about 1000° C. can be used. Examplesof suitable carbon-containing gases include carbon monoxide, aliphatichydrocarbons, both saturated and unsaturated, such as methane, ethane,propane, butane, pentane, hexane, ethylene, acetylene and propylene;oxygenated hydrocarbons such as acetone, and methanol; aromatichydrocarbons such as benzene, toluene, and naphthalene; and mixtures ofthe above, for example carbon monoxide and methane. In general, the useof acetylene promotes formation of multi-walled carbon nanotubes, whileCO and methane are preferred feed gases for formation of single-walledcarbon nanotubes. The carbon-containing gas may optionally be mixed witha diluent gas such as hydrogen, helium, argon, neon, krypton and xenonor a mixture thereof.

The specific reaction temperature used depends on the type of catalystand the type of precursor. Energy balance equations for the respectivechemical reactions can be used to analytically determine the optimum CVDreaction temperature to grow carbon nanotubes. This determines therequired reaction temperature ranges. The optimum reaction temperaturealso depends on the flow rates of the selected precursor and thecatalyst. In general, the method requires CVD reaction temperaturesranging from 500° C. to 1000° C., more preferably reaction temperaturesranging from 700° C. to 900° C.

Synthesis of Carbon Nanotubes

The metal nanoparticles supported on the oxide powder can be aerosolizedand introduced into the reactor maintained at the reaction temperature.Simultaneously, the carbon precursor gas is introduced into the reactor.The flow of reactants within the reactor can be controlled such that thedeposition of the carbon products on the walls of the reactor isreduced. The carbon nanotubes thus produced can be collected andseparated.

The metal nanoparticles supported on the oxide powder can be aerosolizedby any of the art known methods. In one method, the supported metalnanoparticles are aerosolized using an inert gas, such as helium, neon,argon, krypton, xenon, or radon. Preferably argon is used. Typically,argon, or any other gas, is forced through a particle injector, and intothe reactor. The particle injector can be any vessel that is capable ofcontaining the supported metal nanoparticles and that has a means ofagitating the supported metal nanoparticles. Thus, the catalystdeposited on a powdered porous oxide substrate can be placed in a beakerthat has a mechanical stirrer attached to it. The supported metalnanoparticles can be stirred or mixed in order to assist the entrainmentof the catalyst in the transporter gas, such as argon.

Thus, the nanotube synthesis generally occurs as described below andillustrated in FIG. 2. An inert transporter gas 110, preferably argongas, is passed through a particle injector 130. The particle injector130 can be a beaker or other vessel containing the growth catalystsupported on a powdered porous oxide substrate. The powdered porousoxide substrate in the particle injector can be stirred or mixed inorder to assist the entrainment of the powdered porous oxide substratein the argon gas flow. Optionally, the inert gas can be passed through adrying system 120 to dry the gas. The argon gas, with the entrainedpowdered porous oxide, can then be passed through a pre-heater to raisethe temperature of this gas flow to about 400° C. to about 500° C. Theentrained powdered porous oxide is then delivered to the reactionchamber 200. A flow of methane 140 or another carbon source gas,optionally with hydrogen 150 is also delivered to the reaction chamber.The typical flow rates can be 2700 sccm for argon, 1500 sccm formethane, and 500 sccm for He. Additionally, 2500 sccm of argon can bedirected into the helical flow inlets to reduce deposition of carbonproducts on the wall of the reaction chamber. The reaction chamber canbe heated to between about 800° C. and 900° C. during reaction usingheaters 210. The temperature can be 810° C., 820° C., 830° C., 840° C.,850° C., 860° C., 870° C., 880° C., and the like, or any temperature inbetween. The temperature is preferably kept below the decompositiontemperature of the carbon precursor gas. For example, at temperaturesabove 1000° C., methane is known to break down directly into soot ratherthan forming carbon nanostructures with the metal growth catalyst.

Carbon nanotubes and other carbon nanostructures synthesized in reactionchamber 200 then enter the filtration system 220. The filtration systemcan be composed of a single collection vessel or a series of collectionvessels that are connected to outlet of the reaction chamber. Thecollection vessels sort the carbon nanotubes and other outputs byweight. On average, the heaviest reaction products will settle in thefirst collection vessel. The secondary and tertiary vessels will collecton average lighter products. The carbon nanotubes will be relativelylight compared to many of the soot particles generated, so the carbonnanotubes will preferentially collect in the secondary and tertiarycollection vessels.

The collection vessels permit continuous operation of the reactionchamber, as the chamber does not have to be cooled to harvest thesynthesized nanotubes. Instead, the nanotubes can be harvested bychanging the collection vessel. The collection vessels can be connectedvia valves. In order to permit continuous operation, each collectionvessel has outlet valves to allow for connection of two additionalcollection vessels. During typical operation, one outlet valve on eachcollection vessel will be open. As the reaction products flow down fromthe reaction chamber, the collection vessels will capture the variousreaction products, with lighter reaction products tending to accumulatein the secondary or tertiary collection vessel. To harvest reactionproducts from a given collection vessel, the first outlet valve isclosed and the second outlet valve is opened. This diverts the flow ofreaction products into a second collection vessel. The first collectionvessel can then be opened for harvesting of the reaction products whilestill synthesizing additional carbon nanostructures.

Separation of Reaction Products

The collection vessels permit continuous operation of the reactionchamber as the chamber does not have to be cooled to harvest thesynthesized nanotubes. Instead, the nanotubes can be harvested by eitheremptying the collection vessels or by changing the collection vessel.The collection vessels can be connected via valves. In order to permitcontinuous operation, each collection vessel has outlet valves to allowfor connection of two additional collection vessels. During typicaloperation, one outlet valve on each collection vessel will be open. Asthe reaction products flow down from the reaction chamber, thecollection vessels will capture the various reaction products, withlighter reaction products tending to accumulate in the secondary ortertiary collection vessel. To harvest reaction products from a givencollection vessel, the first outlet valve is closed and the secondoutlet valve is opened. This diverts the flow of reaction products intoa second collection vessel. The first collection vessel can then beopened for harvesting of the reaction products while still synthesizingadditional carbon nanostructures.

The collection vessels are generally cyclone-type separators. Typically,in the cyclone separators, the transport gasses having the carbonnanotubes and byproducts entrailed therein generally enters acylindrical chamber tangentially through an upper inlet. The particlesin the transport gas spin in a vortex and follow a helical, downwardlyinclined path. The heavier particles are forced to the outside wall bycentrifugal force, while the lighter particles remain entrailed in thetransport gases. The centrifugal forces can be described by thefollowing equation: $F_{centrifugal} = \frac{m_{part}V^{2}}{R}$where F is a centrifugal force, m is the mass of the particle, V is thevelocity of the particle, and R is the radius of the spiral motion ofthe particle as it spins down. The heavier particles forced to the wallare then pulled by gravity down the walls and eventually fall to thebottom. The transport gases with the lighter particles still entrailedcan exit through a discharge outlet which extends from atop the cycloneseparator.

Thus, the cyclone separators utilize centrifugal forces and low pressurecaused by spinning motion to separate solid particles of differingdensity, size and shape. A typical cyclone separator that can beutilized to remove entrained particles from a transport gas, such as maybe used in the synthesis of carbon nanotubes, has an inlet pipe and amain body comprising upper cylindrical portion and lower conicalportion. The particle laden gas stream is injected through inlet pipewhich is positioned tangentially to upper cylindrical portion. The shapeof upper cylindrical portion and the conical portion induces the gasstream to spin creating a vortex. Larger or more dense particles areforced outwards to the walls of cyclone separator where the drag of thespinning air as well as the force of gravity causes them to fall downthe walls into an outlet or collector. The lighter or less denseparticles, as well as the gas medium itself, reverses course and passoutwardly through the low pressure center of separator and exitseparator via gas outlet which is positioned in the upper portion ofupper cylindrical portion.

The efficiency of the cyclone separator in removing particles ofdifferent diameters depends on the diameter (D₁) of the cyclone, thediameter (D₂) of the powder outlet, the diameter (D₃) of the inlet, andthe diameter (D₄) of the gas outlet. These dimensions can be varied toalter the diameter of the particles that may be removed by the cyclone.

As will be evident to one of skill in the art, the particles which aresuspended or entrained in a transport gas are not homogeneous in theirparticle size distribution. The fact that particle sizes take on aspectrum of values can necessitate that a plurality of cyclonicseparators be used in a series. For example, the first cyclonicseparator in a series can separate out large particles. The smallerparticles remain entrained in the transport gas and are transported tothe second sequential cyclone. The second sequential cyclone is designedto remove the smaller particles which are entrained in the transportgas. If larger particles are carried over into the second cycloneseparator, then they will typically not be removed by the cycloneseparator but exit the cyclone with the transport gas stream.Accordingly, a plurality of cyclone separators that are attached to thereaction chamber in parallel or in a series can be used to separatecarbon nanotubes from the byproducts of the reaction that are entrainedin a transport gas stream.

The carbon nanotubes and nanostructures produced by the methods andprocesses described above can be used in applications that include FieldEmission Devices, Memory devices (high-density memory arrays, memorylogic switching arrays), Nano-MEMs, AFM imaging probes, distributeddiagnostics sensors, and strain sensors. Other key applications include:thermal control materials, super strength and light weight reinforcementand nanocomposites, EMI shielding materials, catalytic support, gasstorage materials, high surface area electrodes, and light weightconductor cable and wires, and the like.

EXAMPLES

Below are examples of specific embodiments for carrying out the presentinvention. The examples are offered for illustrative purposes only, andare not intended to limit the scope of the present invention in any way.Efforts have been made to ensure accuracy with respect to numbers used(e.g., amounts, temperatures, etc.), but some experimental error anddeviation should, of course, be allowed for.

Example 1

Preparation of the Supported Catalyst

Catalysts were prepared by impregnating support materials in metal saltsolutions. For the bimetallic iron-molybdenum based catalyst supportedon alumina powder (BET surface area of approximately 90 m² g⁻¹), iron(II) sulphate heptahydrate and ammonium heptamolibdate tetrahydrate weredissolved in methanol and the resulting solution was added to a methanolsuspension of aluminum oxide at a molar ratio of Fe:Mo:Al₂O₃ of1:0.21:15. The reaction solution was stirred at room temperature whileflowing a stream of N₂ over the mixture to remove the solvent. Aresultant cake was ground with an agate mortar to obtain a fine powder.The catalyst composition was confirmed by Energy Dispersive X-ray (EDX)analysis in a scanning electron microscope.

Example 2

Synthesis of Carbon Nanotubes

The efficiency of the catalyst for SWNTs growth was tested by CVD methodusing a conventional horizontal furnace. SWNTs were synthesized bypassing a flow of argon diluted with methane over the catalyst at 820°C. fir 30 min. The carbon yield obtained was 32 wt %. The amount ofamorphous and other forms of carbon was small as shown by the electronmicroscope images and by the temperature programmed oxidation (TPO)measurements shown in FIG. 4.

Carbon nanotubes were synthesized by using the experimental setup shownin FIG. 2. Typically, 10 g of the Al₂O₃-supported Fe—Mo catalyst wasplaced in the particle injector mounted with a mechanical stirrer. Thecatalyst was stirred while argon is passed through the particle injectorat a flow rate of 2700 sccm thereby delivering the catalyst at a rate of40 g h⁻¹. The argon flow with the entrained particles is passed througha flexible tube that is wrapped around a central heating coil thatserves as the pre-heater. The pre-heater was set for 600° C. Thepre-heated argon flow with the entrained particles was then passed intothe reaction chamber.

The reaction chamber was pre-heated to 820° C. Argon, at a rate of 2500sccm, was injected through the helical flow inlets into the reactionchamber. Argon as a transport gas for catalysts, at the rate of 2700sccm, was injected through the injector to the chamber. The synthesiswas begun by flowing a mixture at CH₄ at a flow rate of 1500 sccm intothe reaction chamber. The temperature and gas flows were maintained for120 minutes in order to form carbon nanostructures. The single-walledcarbon nanotubes were collected using the product separators. Anaccumulation of large quantities of dark black, silver-black and verylight grey products were observed in container 1, container 2, and thetrap respectively. The final product was separated from theAl₂O₃-support powder by treatment with hydro fluoric acid (HF). Carbonnanotubes were made with high purity of up to 95 wt %. High resolutiontransmission electron microscopy images (TEM, FIG. 3) show that SWNTswith an average bundle diameter of approximate 7 nm.

The TPO curves for the as-prepared carbon SWNTs collected from the firsttwo containers, and the trap, which is the third container, is shown inFIG. 3 a. The carbon content of the product varies in the soot collectedfrom container 1, container 2, and the trap, with the correspondingcarbon yields of approximately 15, 8, and 5 wt. %, respectively, andvarying the gas flow rate into the reactor changes the metal content ofthe resultant samples.

Removal of the impurities by HF treatment and selective oxidation,followed by mild acid (HCl) treatment, the oxidation temperature for theSWNTs from container 1 dramatically shifts to approximately 610° C.(FIG. 3 b), thereby confirming the high quality of the SWNTs produced.

Raman spectroscopy measurement, with laser excitation wavelengths in therange from 488 to 1064 nm, shown in FIG. 4, also are consistent withhigh quality carbon SWNTs being produced. The ratio between theintensities of the G-band (near 1590 cm⁻¹) and D-band (1260-1350 cm⁻¹)is very high (I_(G)/I_(D)=9-11). The weak D-ban intensity in the Ramanspectra is consistent with the presence of very low amounts ofdisordered sp² carbon forms in the sample. The Raman active radialbreathing modes (RBM) and their relative intensities are consistent withnarrow distribution of SWNTs, ranging from 0.8 to 1.2 nm (190-290 cm⁻¹),are present in the trap, while the spectra corresponding to samples fromcontainer 1 and container 2 indicate a wider distribution of diametersfrom about 0.8 to 2 nm (118-290 cm⁻¹). Further, according to the TPOresults, the synthesis duration is the shortest for the sample collectedfrom the trap, indicating that nucleation of SWNTs with smallerdiameters occurred first during the synthesis resulting in carbon SWNTswith smaller diameters. Thus, the methods above are for the large scaleproduct of carbon SWNTs with small diameters and narrow diameter ranges.

While the invention has been particularly shown and described withreference to a preferred embodiment and various alternate embodiments,it will be understood by persons skilled in the relevant art thatvarious changes in form and details can be made therein withoutdeparting from the spirit and scope of the invention. All printedpatents and publications referred to in this application are herebyincorporated herein in their entirety by this reference.

1. A chemical vapor deposition method for the preparation of single-wallcarbon nanotubes (SWNT), the method comprising: contacting a carbonprecursor gas with a supported bimetallic catalyst in a reaction chamberand at a reaction temperature wherein the supported bimetallic catalystis entailed in a gas, and wherein SWNTs of small diameter are formed. 2.The method of claim 1, wherein the carbon precursor gas is methane. 3.The method of claim 2, wherein the carbon precursor gas furthercomprises an inert gas.
 4. The method of claim 3, wherein the inert gasis argon, helium, nitrogen, hydrogen, or combinations thereof.
 5. Themethod of claim 1, wherein the bimetallic catalyst is iron andmolybdenum.
 6. The method of claim 1, wherein the catalyst has aparticle size between 1 nm to 10 nm.
 7. The method of claim 6, whereinthe catalyst has a particle size of about 5 nm.
 8. The method of claim6, wherein the catalyst has a particle size of about 3 nm.
 9. The methodof claim 6, wherein the catalyst has a particle size of about 1 nm. 10.The method of claim 1, wherein the support is a powdered oxide.
 11. Themethod of claim 10, wherein the powdered oxide is selected from thegroup consisting of Al₂O₃, SiO₃, MgO and zeolites.
 12. The method ofclaim 11, wherein the powdered oxide is Al₂O₃.
 13. The method of claim1, wherein the bicatalyst is Fe—Mo and the biocatalyst and the supportare in a ratio of about 1:1 to about 1:50.
 14. The method of claim 1,wherein the carbon precursor gas has a flow rate of about 500 sccm toabout 3000 sccm.
 15. The method of claim 14, wherein the supportedcatalyst has a flow rate into the reaction chamber of about 20 g h⁻¹ toabout 60 g h⁻¹.
 16. The method of claim 1, wherein the temperature isabout 800° C. to about 900° C.